Electrical conductor and core for an electrical conductor

Abstract

A core for an electrical conductor. The core includes an inner core component, an intermediate cladding component and an outer cladding component. The inner core component comprises a plurality of glass based stranded members in a first resin matrix. The intermediate cladding component surrounds the inner core component and comprises a plurality of carbon stranded members in a second resin matrix. The outer cladding component surrounds the intermediate cladding component and comprises a plurality of glass based stranded members in a third resin matrix. The first resin matrix and the second resin matrix are substantially independent of each other, meeting at a boundary. An electrical conductor as well as a manufacturing method is likewise disclosed.

1. A core for an electrical conductor comprising:
 an inner core component comprising a plurality of glass based stranded members in a first resin matrix; 
 an intermediate cladding component surrounding the inner core component and comprising a plurality of carbon stranded members in a second resin matrix; and 
 an outer cladding component surrounding the intermediate cladding component and comprising a plurality of glass based stranded members in a third resin matrix, 
 wherein the first resin matrix and the second resin matrix are substantially independent of each other and meet at a boundary. 
 
   
   
     2. The core of  claim 1  wherein the first resin matrix and the second resin matrix comprise different materials. 
   
   
     3. The core of  claim 1  wherein the inner core component comprises a plurality of substantially boron free E-glass stranded members. 
   
   
     4. The core of  claim 3  wherein the inner core component predominantly comprises a plurality of substantially boron free E-glass stranded members. 
   
   
     5. The core of  claim 1  wherein the outer cladding component comprises a plurality of substantially boron free E-glass stranded members. 
   
   
     6. The core of  claim 5  wherein the outer cladding component predominantly comprises a plurality of substantially boron free E-glass stranded members. 
   
   
     7. The core of  claim 1  further comprising a protective coating extending around the outer cladding component. 
   
   
     8. The core of  claim 1  wherein each of the intermediate cladding and the outer cladding include a cross-sectional area, and wherein the cross-sectional area of the intermediate cladding component is substantially identical to the cross-sectional are of the outer cladding component. 
   
   
     9. The core of  claim 1  wherein the first matrix comprises a UV cured resin, and, wherein the second matrix and the third matrix each comprise a non-UV cured resin. 
   
   
     10. The core of  claim 1  wherein the inner core includes at least one of E-glass, D-Glass, E-CR glass, S-glass, R-glass, RH-glass, S2-glass. 
   
   
     11. The core of  claim 1  wherein the inner core is substantially free of carbon fiber strands. 
   
   
     12. The core of  claim 1  wherein at least one of the intermediate cladding and the outer cladding is helically wound at an angle of between 1° and 40°. 
   
   
     13. The core of  claim 1  wherein the intermediate cladding comprises a plurality of radially outward layers. 
   
   
     14. An electrical conductor comprising a core surrounded by an electrical conductor, the core further comprising:
 an inner core component comprising a plurality of glass based stranded members in a first resin matrix; 
 an intermediate cladding component surrounding the inner core component and comprising a plurality of carbon stranded members in a second resin matrix; and 
 an outer cladding component surrounding the intermediate cladding component and comprising a plurality of glass based stranded members in a third resin matrix, 
 wherein the first resin matrix and the second resin matrix are substantially independent of each other and meet at a boundary. 
 
   
   
     15. The electrical conductor of  claim 12  wherein the electrical conductor comprises a plurality of strands which extend around the outer cladding component. 
   
   
     16. The core of  claim 14  wherein the first resin matrix and the second resin matrix comprise different materials. 
   
   
     17. The core of  claim 14  wherein the inner core component comprises a plurality of substantially boron free E-glass stranded members. 
   
   
     18. The core of  claim 17  wherein the inner core component predominantly comprises a plurality of substantially boron free E-glass stranded members. 
   
   
     19. The core of  claim 14  wherein the outer cladding component comprises a plurality of substantially boron free E-glass stranded members. 
   
   
     20. The core of  claim 19  wherein the outer cladding component predominantly comprises a plurality of substantially stranded members selected from the group consisting of: E-glass, D-Glass, E-CR glass, S-glass, R-glass, RH-glass, and S2-glass. 
   
   
     21. The core of  claim 14  further comprising a protective coating extending around the outer cladding component. 
   
   
     22. The core of  claim 14  wherein each of the intermediate cladding and the outer cladding include a cross-sectional area, and wherein the cross-sectional area of the intermediate cladding component is substantially identical to the cross-sectional are of the outer cladding component. 
   
   
     23. The core of  claim 14  wherein the first matrix comprises a UV cured resin, and, wherein the second matrix and the third matrix each comprise a non-UV cured resin. 
   
   
     24. The core of  claim 14  wherein the inner core includes at least one of E-glass, D-Glass, E-CR glass, S-glass, R-glass, RH-glass, S2-glass. 
   
   
     25. The core of  claim 14  wherein the inner core is substantially free of carbon fiber strands. 
   
   
     26. The core of  claim 14  wherein at least one of the intermediate cladding and the outer cladding is helically wound at an angle of between 1° and 40°. 
   
   
     27. The core of  claim 14  wherein the intermediate cladding comprises a plurality of radially outward layers. 
   
   
     28. A method of forming a core for an electrical conductor comprising the steps of:
 forming an inner core component from a plurality of first fiber strands embedded within a first resin matrix; 
 at least partially curing the resin matrix of the inner core component; 
 forming an intermediate cladding component having a plurality of second fiber strands embedded within a second resin matrix about the inner core component; 
 forming an outer cladding component having a plurality of third fiber strands embedded within a third resin matrix about the intermediate cladding component; and 
 curing resin matrix of each of the intermediate cladding component and the outer cladding component. 
 
   
   
     29. The method of  claim 28  wherein the step of at least partially curing the inner core component further comprises the step of fully curing the inner core component. 
   
   
     30. The method of  claim 28  wherein the step of at least partially curing the inner core component comprises the step of UV curing. 
   
   
     31. The method of  claim 28  wherein the steps of forming an intermediate cladding and of forming an outer cladding component occur substantially simultaneously. 
   
   
     32. The method of  claim 28  further comprising the step of coating the outer cladding component. 
   
   
     33. The method of  claim 28  wherein at least one of the two steps of forming further comprises the step of helically winding the fiber strands of a respective intermediate cladding component and the outer cladding component.